Solid Electrolyte Battery Cell Assembly With Radiation-Cured Layers
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Solution Overview
Problem
Conventional battery cells with liquid electrolytes face challenges such as leakage, flammability, toxicity, and ignition risks, along with high internal resistance, making them hazardous and inefficient.
Innovation Solution
A method for manufacturing solid electrolyte battery cells using a pasty state electrode layer with ion-conducting liquid electrolyte mixtures and polymerization initiators, where the electrode layers are exposed to radiation for solidification, creating a separation layer that ensures excellent ionic conduction and avoids electronic conduction between electrodes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If liquid electrolyte is used in battery cells, then ionic conduction is achieved, but leakage, flammability, and toxicity risks occur
Solution Approach 1:
The patent changes the physical state of the electrolyte from liquid to solid through polymerization. The liquid electrolyte mixture is deposited in a pasty state and then solidified by UV radiation or heat treatment, transforming it into a solid polymer electrolyte membrane that eliminates leakage and flammability risks while maintaining ionic conduction properties
Solution Approach 2:
The electrolyte undergoes a phase transition from liquid to solid state. The process involves depositing the electrolyte in a liquid or pasty state, then applying UV radiation or heat to induce polymerization and solidification, creating a solid polymer electrolyte that retains ion conductivity while eliminating the hazards associated with liquid electrolytes
2Productivity
If liquid electrolyte is used, then manufacturing is simplified, but internal resistance increases and efficiency decreases
Solution Approach 1:
The patent modifies the electrolyte composition by incorporating polymer matrices and controlling the solidification process to create a dense, uniform solid polymer electrolyte structure. This reduces internal resistance by improving ion transport pathways while maintaining manufacturing efficiency through the continuous deposition and solidification process
3Reliability
If solid electrolyte is used, then safety is improved, but manufacturing complexity increases due to polymerization process
Solution Approach 1:
The patent replaces traditional mechanical sealing and containment systems with a chemically bonded solid polymer electrolyte membrane. The polymerization process creates inherent structural integrity and sealing without requiring additional mechanical components, reducing overall device complexity despite the added chemical processing step
Solution Approach 2:
The patent uses UV radiation or heat fields as energy fields to drive the polymerization and solidification process, replacing the need for complex mechanical pressure or temperature control systems. The energy field approach simplifies the manufacturing equipment compared to traditional high-pressure or cryogenic solidification methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method reduces internal resistance, enhances safety by eliminating liquid electrolyte risks, and improves manufacturing efficiency, achieving performance comparable to liquid electrolyte cells while being safer and more cost-effective.
Implementation Method 1
depositing, on one face of the first electrically conductive support, a cathode layer in a pasty state, comprising a cathode active material, carbonaceous electrically conductive fillers, a first ion-conducting liquid electrolyte mixture, a first monomer or polymer mixture and a first polymerization or crosslinking initiator of the first monomer or polymer mixture; exposing the cathode layer in a pasty state by means of a first radiation adapted to the first polymerization or crosslinking initiator of the first monomer mixture, so as to initiate solidification of the cathode layer
Data Source
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AI summary
The invention relates to a method and an apparatus for assembling battery cells, the method comprising forming electrode layers in a pasty state on electrically conductive supports, these electrode layers comprising mixtures of ion-conductive liquid electrolytes, monomer or polymer mixtures, and initiators of polymerisation or cross-linking of the monomer or polymer mixtures, the electrode layers being exposed to a radiation initiating their solidification then placed in contact with a separation layer in the liquid state before completion of their respective solidifications, in such a way as to obtain a solid electrolyte battery cell having properties close to those of liquid electrolyte battery cells.